TROUBLESHOOTING
CLUTCH
S No |
PROBLEM |
PROBABLE CAUSES |
REMEDIES |
1 |
Noise while pressingthe clutch pedal |
Lack of lubrication in Clutch Release Bearing |
Lubricate |
Clutch Release Bearing damage |
Replace |
||
2 |
Noise while releasingclutch pedal |
Lack of lubrication in Pilot Bearing |
Lubricate |
Pilot Bearing damage |
Replace |
||
Clutch disk hub loose on Input shaft |
Replace the worn out parts |
||
3 |
Clutch slippage |
Clutch Pedal free play |
Adjust & correct (25 to 35 mm) |
Broken or Weak pressure spring |
Replace springs |
||
Release lever height incorrect |
AdjUSt & COrreCt (SC.40to44mm)(DC28to36mm) |
||
Grease or oil on facings |
Replace the facing, check source of |
||
Glazed clutch facing |
Replace facing |
||
Glazed flywheel or Pressure plate face |
Correct by machining or replace |
||
Wraped Clutch facing |
Replace the clutch facing |
||
Wraped Flywheel or Pressure plate face |
Correct by machining or replace |
||
4 |
Clutch not disengagewhile pressing clutch |
Clutch Pedal free play more |
Adjust & correct |
Release lever height setting improper |
Adjust & correct |
||
5 |
Wear of clutch facing |
Driver Clutch pedal riding |
Keep foot off clutch pedal |
Excessive and incorrect use of clutch |
Reduce use |
||
Cracks in flywheel or pressure plate face |
Correct by machining or replace |
||
Weak or broken pressure spring |
Replace spring |
||
Clutch pedal free play less |
Adjust & correct |
||
6 |
Clutch pedal hard |
Lack of lubrication in pedal linkage |
Lubricate |
Clutch pedal jam on clutch shaft |
Grease the shaft |
||
Release lever height setting improper |
Adjust & correct |
||
7 |
Clutch Pedal Pulsation |
Engine and Transmission not improper |
Realign |
Flywheel face run out more |
Correct run out or replace |
||
Release lever not evenly adjusted |
Adjust & correct |
||
Pressure plate assembly misaligned |
Realign |
||
Warped pressure plate or clutch facing |
Replace |
||
Clutch plate nut free on |
De and check clean |
||
Workest clutch facing |
|||
BRAKES
S.No. |
PROBLEM |
PROBABLE CAUSES |
REMEDIES |
1. |
NO BRAKING ACTION |
Pedal linkage broken or disconnected |
Replace or Repair |
2. |
POOR BRAKING ACTION |
Brake setting improper |
Adjust & correct |
Glazed brake liners |
Replace |
||
Glazed brake disc |
Correct by machining or replace |
||
3. |
BRAKE STUCKING |
Linkage retracting spring loose |
Replace springs |
Brake disc plate spring tension less |
Replace springs |
||
Binding in linkage |
Lubricate & free |
||
4. |
NOISE WHILE BRAKING |
Loose rivets of brake lining |
Correct or replace |
Worn out brake lining |
Replace |
||
Rough or worn out brake disc plate |
Correct by machining or replace |
||
Foreign matter imbedded in lining |
Clean the liners |
||
Loose part in the system. |
Tighten the loose |
BRAKE & CLUTCH PEDAL
S. No. |
PROBLEM |
PROBABLE CAUSES |
REMEDIES |
1 |
Noise while pressing the clutch pedal |
Lack of lubrication in Clutch Release Bearing |
Lubricate |
Clutch Release Bearing damage |
Replace |
||
2 |
Noise while releasing clutch pedal |
Lack of Lubrication in Pilot Bearing |
Lubricate |
Pilot Bearing damage |
Replace |
||
Clutch disc hub loose on input shaft |
GEARBOX
S.No. |
PROBLEM |
PROBABLE CAUSES |
REMEDIES |
1 |
NOISE |
||
Humming |
Wear on gear teeth flank |
Replace the gear. |
|
(a pecutior noise) |
Damage on gear teeth flank |
Replace the gear. |
|
Metallic grinding |
Oil lever low. |
Top up oil lever. |
|
Whine (Bullet passing sound) |
Backlash less |
Correct the back lash either by replacing gears on housing. |
|
Gear machining improper |
Replace the gear. |
||
Hissing |
Worn out bearing |
Replace the gearing. |
|
(Leaking noise tent-tire to air lack) |
Bearing ball/race pitted |
Replace the gearing. |
|
Ratting (Ruppict series of short loud noise) |
Backlash more |
Correct the back lash either by |
|
replacing gears or housing. |
|||
Bearing seat loosen |
Replace the gearing or replace the housing. |
||
Bearing play more |
Replace the gearing. |
||
Excessive end play |
Correct the end play by tightening the Hex retaining nut or replacing spacers/gears. |
||
Knocking (Noise of sharp blue) |
Dent on the Gear Tooth |
Remove the dent by polishing. |
|
Gear tooth damage |
Replace the gear. |
||
Foreign matters present |
Clean the Gear train and strain the Oil. |
||
Insufficient oil. |
Top up the oil. |
||
Detent Lock assy. Tight |
Replace detent-retaining spring. |
||
Bent in Shifter rod |
Replace the shifter rod. |
||
Gear tooth battered |
Replace the gear. |
||
2 |
HARD SHIFTING |
Sliding Gears tight on shaft |
Free the Gears shaft by polishing or by replacing gear/shaft. |
Pilot Bearing Jam |
Replace the gearing |
||
Excessive Clutch Free Paly |
Adjust & correct Free Play. |
||
Inter-lock pin tight |
Loosen the pin by polishing. |
||
Clutch is not disengaging. |
Adjust & Correct |
||
Incomplete Gear Engaging |
Engage Gear fully. |
||
Weak Detent Retaining spring |
Replace the spring. |
||
3 |
GEAR SLIPPING OUT |
Shifter rod retaining groove worn out |
Replace shifter rod. |
Gear teeth rounded off |
Replace the gear. |
||
Worn out / Bent Shifter Fork |
Replace the Shifter Fork. |
||
Detent balls/ spring stuck |
Free & Lubricate. |
||
4 |
GEAR STICKING |
Scoring on Fork. |
Replace fork |
Clutch not disengaging. |
Adjust & correct. |
DIFFERENTIAL
S.NO. |
TROUBLE |
PROBABLE CAUSE |
REMEDIES |
1 |
HUMMING |
1 .Incorrect adjustment of Crown Wheel & |
1 .Re-adjust as per the procedure. |
Tail Pinion. 2.Tooth contact pattern not correct. |
2.Correct the tooth contact pattern by doing the adjustment as per the procedure. |
||
2 |
NOISE WHILE ACCELERATING |
Tooth contact shifted towards thick end. |
Adjust Tooth Contact pattern as per the procedure. |
3 |
NOISE WHILE DE-ACCELERATING |
Tooth contact shifted towards thin end. |
Adjust Tooth Contact pattern as per the procedure |
1 .Bevel Pinion tight on Bevel Gear. |
1 .Correct the gap. |
||
NOISE WHILE |
2.Damaged teeth of Bevel |
2.Replace the damaged gear. |
|
4 |
TURNING |
3. Excessive backlash between Bevel Pinion |
3.Correct the backlash. |
and Bevel Gear |
4.Replace the bearing. |
||
4.Defective axle bearing |